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KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30462-A30600) – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30462-A30600
- PUBLICATION NUMBER:CEBM017909
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Description
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30462-A30600)
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30462-A30600) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30462-A30600)
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used.
- Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel.
- It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
- The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 930E-4 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30462-A30600)
COVER............................................................................... 1 FOREWORD............................................................................ 5 TABLE OF CONTENTS................................................................... 7 SECTION A GENERAL INFORMATION....................................................... 9 MAJOR COMPONENTS & SPECIFICATIONS............................................... 11 TRUCK AND ENGINE............................................................ 11 MAIN ALTERNATOR............................................................. 11 AC INDUCTION TRACTION MOTORIZED WHEELS...................................... 11 SUSPENSION.................................................................. 11 OPERATOR’S CAB.............................................................. 11 POWER STEERING.............................................................. 11 DYNAMIC RETARDING........................................................... 11 BRAKE SYSTEM................................................................ 11 ENGINE.................................................................. 13 AC ELECTRIC DRIVE SYSTEM................................................ 13 DYNAMIC RETARDING....................................................... 13 BATTERY ELECTRIC SYSTEM................................................. 13 SERVICE CAPACITIES...................................................... 13 HYDRAULIC SYSTEMS....................................................... 14 SERVICE BRAKES.......................................................... 14 STEERING................................................................ 14 TIRES................................................................... 14 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS............................ 14 WEIGHT DISTRIBUTION..................................................... 15 SAFETY.......................................................................... 17 GENERAL..................................................................... 17 Safety Rules............................................................ 17 Safety Features......................................................... 17 Fire Extinguisher And First Aid Kit..................................... 17 Clothing And Personal Items............................................. 17 Leaving The Operator’s Seat............................................. 18 Mounting And Dismounting................................................ 18 Fire Prevention For Fuel And Oil........................................ 18 Precautions With High Temperature Fluids................................ 19 Asbestos Dust Hazard Prevention......................................... 19 Prevention Of Injury By Work Equipment.................................. 19 Unauthorized Modification............................................... 19 Precautions When Using ROPS............................................. 19 Precautions For Attachments............................................. 20 Precautions For Starting The Truck...................................... 20 PRECAUTIONS BEFORE OPERATION................................................ 20 Safety At The Worksite.................................................. 20 Fire Prevention......................................................... 21 Ventilation In Enclosed Areas........................................... 21 Preparing For Operation................................................. 21 Mirrors, Windows And Lights............................................. 21 In The Operator Cab (Before Starting The Engine)........................ 21 Seat Belts.............................................................. 21 OPERATING THE TRUCK......................................................... 22 When Starting The Engine................................................ 22 General Truck Operation................................................. 22 Ensuring Good Visibility................................................ 22 Traveling............................................................... 23 Traveling In Reverse.................................................... 23 Traveling On Slopes..................................................... 23 Operating On Snow Or Ice................................................ 23 Avoid Damage To Dump Body............................................... 23 Driving Near High Voltage Cables........................................ 24 Working On Loose Ground................................................. 24 When Dumping............................................................ 24 When Loading............................................................ 24 Parking The Truck....................................................... 24 Towing.................................................................. 24 WORKING NEAR BATTERIES...................................................... 25 Battery Hazard Prevention............................................... 25 Jump Starting With Booster Cables....................................... 26 Jump Starting With Receptacles.......................................... 26 BEFORE PERFORMING MAINTENANCE............................................... 27 Stopping The Engine Before Service...................................... 27 Warning Tag............................................................. 27 Proper Tools............................................................ 27 Use of Tie-Off Anchor During Maintenance and Repair..................... 27 Securing The Dump Body.................................................. 28 WHILE PERFORMING MAINTENANCE................................................ 29 Keep The Truck Clean.................................................... 29 Attachments............................................................. 29 Working Under The Truck................................................. 29 Rotating Fan And Belts.................................................. 29 Waste Materials......................................................... 29 Adding Fuel Or Oil...................................................... 30 Radiator Coolant Level.................................................. 30 Use Of Lighting......................................................... 30 Precautions With The Battery............................................ 30 Handling High Pressure Hoses............................................ 30 Precautions With High Pressure Oil...................................... 30 Performing Maintenance Near High Temperature Or High Pressure........... 30 TIRES....................................................................... 31 Handling Tires.......................................................... 31 Tire Maintenance........................................................ 31 Storing Tires After Removal............................................. 31 WHEN REPAIRS ARE NECESSARY.................................................. 32 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.......................... 33 Preliminary Procedures Before Welding or Performing Maintenance......... 33 Engine Shutdown Procedure Before Welding or Performing Maintenance...... 33 CAPACITOR DISCHARGE SYSTEM.................................................. 35 Necessary Tools......................................................... 35 Warnings And Cautions................................................... 36 Manual DC Link Capacitor Discharge Procedure............................ 37 Failure of the Discharge System......................................... 39 Manual Discharge of Capacitors.......................................... 40 Short Isolated Capacitor Terminals...................................... 42 OPERATING INSTRUCTIONS.......................................................... 43 PREPARING FOR OPERATION..................................................... 43 WALK AROUND INSPECTION...................................................... 43 ENGINE START-UP............................................................. 47 AFTER ENGINE HAS STARTED.................................................... 48 PRE-SHIFT BRAKE CHECK (if equipped)......................................... 48 Events.................................................................. 48 OPERATION................................................................... 49 Description............................................................. 49 Brake Test Exit Criteria................................................ 49 PERFORMING THE BRAKE TESTS.................................................. 50 Setup................................................................... 50 Service Brake Test...................................................... 50 Parking Brake Test...................................................... 51 Retard System Test...................................................... 52 EMERGENCY STEERING SYSTEM................................................... 52 Operation............................................................... 52 Pre-Operation Testing................................................... 52 MACHINE OPERATION SAFETY PRECAUTIONS........................................ 53 OPERATING ON THE HAUL ROAD.................................................. 54 STARTING ON A GRADE WITH A LOADED TRUCK..................................... 55 PASSING..................................................................... 55 LOADING..................................................................... 55 Overload Speed Limit Function........................................... 55 DUMPING..................................................................... 56 Raising The Dump Body................................................... 56 Lowering The Dump Body (When dumping on flat ground):................... 57 Lowering The Dump Body (When dumping over a berm or into a crusher):.... 57 TOWING...................................................................... 58 SAFE PARKING PROCEDURES..................................................... 58 NORMAL ENGINE SHUTDOWN PROCEDURE............................................ 59 DELAYED ENGINE SHUTDOWN PROCEDURE........................................... 59 SUDDEN LOSS OF ENGINE POWER................................................. 60 FUEL DEPLETION.............................................................. 60 DISABLED TRUCK DUMPING PROCEDURE............................................ 61 Hookup.................................................................. 61 Raising the Body........................................................ 61 Lowering the Body....................................................... 61 WARNINGS AND CAUTIONS........................................................... 63 GRADE/SPEED CHART........................................................... 63 KEY SWITCH.................................................................. 63 ROPS/FOPS................................................................... 63 BATTERIES................................................................... 64 CAPACITORS.................................................................. 64 CRUSHING HAZARD............................................................. 65 CYLINDER PRESSURE........................................................... 65 FILLING THE HYDRAULIC TANK.................................................. 66 HYDRAULIC OIL PRESSURE...................................................... 66 HOT OIL SPRAY............................................................... 67 WHEEL MOTOR OIL LEVEL....................................................... 67 HOT EXHAUST................................................................. 67 RADIATOR.................................................................... 67 EMERGENCY LADDER............................................................ 67 ACCUMULATOR DRAIN VALVES.................................................... 67 EMERGENCY DUMP PROCEDURE.................................................... 68 EMERGENCY TOWING PROCEDURE.................................................. 68 WELDING..................................................................... 68 EMERGENCY SHUTDOWN.......................................................... 68 INFORMATION DISPLAY......................................................... 69 WIRELESS SIGNALS............................................................ 69 HIGH VOLTAGE................................................................ 69 LIFTING INSTRUCTIONS........................................................ 70 PRODUCT IDENTIFICATION PLATE................................................ 71 LUBRICATION CHART........................................................... 72 TORQUE TABLES AND CONVERSION CHARTS............................................. 73 STORAGE AND IDLE MACHINE PREPARATION............................................ 83 SHORT TERM IDLE PERIODS..................................................... 83 PREPARATION FOR STORAGE..................................................... 84 REMOVAL FROM STORAGE........................................................ 85 RECONDITIONING AN IDLE VEHICLE.............................................. 87 ENGINE OPERATION............................................................ 89 After The Engine Has Started............................................ 90 ENGINE STORAGE.............................................................. 91 Temporary Storage (30 Days Or Less)..................................... 91 Extended Storage (More Than 30 Days).................................... 91 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................. 93 ELECTRIC DRIVE TRUCKS....................................................... 94 Storing A Truck That Is Operational..................................... 94 Storing A Truck That Is Not Operational................................. 95 Storing A Major Component............................................... 96 Periodic Inspections.................................................... 96 Placing Equipment Into Service After Storage............................ 96 SECTION B STRUCTURES................................................................ 99 SECTION B2 STRUCTURAL COMPONENTS................................................ 101 STRUCTURAL COMPONENTS....................................................... 103 PREPARATION............................................................. 103 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY............................... 104 Removal............................................................. 104 Installation........................................................ 104 RH DECK AND RETARDING GRID.............................................. 105 Removal............................................................. 105 Installation........................................................ 105 LH DECK................................................................. 106 Removal............................................................. 106 Installation........................................................ 106 CENTER DECK............................................................. 107 Removal............................................................. 107 Installation........................................................ 107 SECTION B3 DUMP BODY............................................................ 109 DUMP BODY................................................................... 111 DUMP BODY............................................................... 111 Removal............................................................. 111 Installation........................................................ 112 BODY PADS............................................................... 114 Body Pad Shimming Procedure......................................... 115 BODY GUIDE.............................................................. 116 HOIST LIMIT SWITCH...................................................... 116 BODY-UP SWITCH.......................................................... 116 BODY RETENTION SLING.................................................... 116 ROCK EJECTORS........................................................... 117 Inspection.......................................................... 117 SECTION B4 FUEL TANK............................................................ 119 FUEL TANK................................................................... 121 FUEL TANK............................................................... 121 Removal............................................................. 121 Repair.............................................................. 121 Cleaning............................................................ 121 Installation........................................................ 121 FUEL TANK VENT ASSEMBLY................................................. 123 Disassembly......................................................... 123 Assembly............................................................ 123 FUEL GAUGE SENDER....................................................... 124 Removal............................................................. 124 Installation........................................................ 124 QUICK FILL FUEL RECEIVERS............................................... 124 SECTION C ENGINE.................................................................... 125 SECTION C2 POWER MODULE......................................................... 127 POWER MODULE................................................................ 129 PREPARATION FOR REMOVAL................................................. 129 REMOVAL................................................................. 134 INSTALLATION............................................................ 136 HOOKUP.................................................................. 137 SECTION C3 COOLING SYSTEM....................................................... 139 COOLING SYSTEM.............................................................. 141 RADIATOR................................................................ 141 Removal............................................................. 141 Installation........................................................ 143 Filling Procedure................................................... 144 REPAIRING THE RADIATOR.................................................. 144 Internal Inspection................................................. 144 External Cleaning................................................... 144 Disassembly......................................................... 145 Cleaning and Inspection............................................. 146 Assembly............................................................ 146 Pressure Testing.................................................... 147 COOLANT SYSTEM TROUBLESHOOTING.......................................... 147 SECTION C4 POWER TRAIN.......................................................... 149 POWER TRAIN................................................................. 151 ALTERNATOR REMOVAL...................................................... 151 ALTERNATOR INSTALLATION................................................. 153 Measuring Procedure................................................. 153 Joining the Alternator and Engine................................... 155 ENGINE.................................................................. 156 Removal............................................................. 156 Service............................................................. 156 Installation........................................................ 156 SECTION C5 AIR CLEANERS......................................................... 157 AIR CLEANERS................................................................ 159 OPERATION............................................................... 159 SERVICING THE AIR CLEANERS.............................................. 159 Replacing The Filter Element........................................ 159 Cleaning The Main Filter Element.................................... 161 Servicing The Precleaner Section.................................... 162 EVACUATOR VALVES (if equipped).......................................... 163 AIR INTAKE TROUBLESHOOTING.............................................. 163 SECTION C7 FAN CLUTCH........................................................... 165 FAN CLUTCH.................................................................. 167 REMOVAL & INSTALLATION TOOLING.......................................... 167 DISASSEMBLY............................................................. 170 CLEANING AND INSPECTION................................................. 180 ASSEMBLY................................................................ 184 TEST PROCEDURE.......................................................... 198 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................. 199 SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM....................................... 201 24VDC ELECTRICAL SUPPLY SYSTEM.............................................. 203 ELECTRICAL SYSTEM DESCRIPTION........................................... 203 BATTERIES............................................................... 203 Maintenance and Service............................................. 203 Troubleshooting..................................................... 203 BATTERY SUPPLY SYSTEM................................................... 205 24VDC Battery Charging Alternator................................... 205 Batteries........................................................... 205 24VDC Auxiliary Battery Receptacles................................. 205 Battery Disconnect Switches......................................... 206 Isolation Diode..................................................... 206 Engine Start Relay.................................................. 206 24VDC to 12VDC Converter............................................ 206 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)..................... 207 Operation........................................................... 207 Pressure Switch..................................................... 207 Check Valve......................................................... 207 Timer Solenoid...................................................... 207 MAINTENANCE............................................................. 208 Prelube System Operation Checks..................................... 208 Check Valve......................................................... 208 Timer Solenoid...................................................... 208 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.............................. 209 24VDC ELECTRIC START SYSTEM................................................. 211 CRANKING MOTORS......................................................... 211 Operation........................................................... 211 Removal............................................................. 211 Installation........................................................ 211 CRANKING MOTOR TROUBLESHOOTING.......................................... 212 Preliminary Inspection.............................................. 212 No-Load Test........................................................ 212 Interpreting Results of Tests....................................... 213 Disassembly......................................................... 213 Cleaning and Inspection............................................. 214 Armature Servicing.................................................. 216 Field Coil Checks................................................... 216 Field Coil Removal.................................................. 216 SOLENOID CHECKS......................................................... 217 Test................................................................ 217 Assembly............................................................ 218 Bearing Replacement:................................................ 218 Motor Assembly:..................................................... 218 Pinion Clearance.................................................... 219 MAGNETIC SWITCH......................................................... 219 Removal............................................................. 219 Installation........................................................ 219 Coil Test........................................................... 220 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS................................... 221 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................... 223 TRUCK SHUTDOWN PROCEDURE................................................ 223 BRAKE WARNING BUZZER.................................................... 223 AUXILIARY CONTROL CABINET COMPONENTS.................................... 223 Power Distribution Terminals........................................ 223 Engine Starter Failure Delay Timer.................................. 223 5 Minute Idle Timer................................................. 224 Pulse Voltage Modulator (PMV)....................................... 224 Control Power Relay................................................. 224 Auto Lube Timer..................................................... 224 Diode Board - DB1................................................... 226 Fuse Blocks......................................................... 227 Alarm Indicating Device (AID) System................................ 227 Diode Matrix (With Sound)........................................... 228 Diode Matrix (Without Sound)........................................ 228 Hot Switch Inverter................................................. 228 Hot Switch Inverter (Not Used)...................................... 229 Temperature and Latch............................................... 229 RELAY BOARDS............................................................ 230 Relay Boards RB1, RB3, RB4, RB5..................................... 230 Relay Board RB6, RB7, RB8, RB9...................................... 232 Relay Board Functions............................................... 233 BODY-UP SWITCH.......................................................... 235 Operation........................................................... 235 Adjustment.......................................................... 235 Service............................................................. 235 HOIST LIMIT SWITCH...................................................... 236 Operation........................................................... 236 Adjustment.......................................................... 236 Service............................................................. 236 FUSES AND CIRCUIT BREAKERS.............................................. 237 SECTION D10 BATTERY CHARGING ALTERNATOR......................................... 241 BATTERY CHARGING SYSTEM..................................................... 245 BATTERY CHARGING SYSTEM................................................. 245 ELECTRICAL SYSTEM DESCRIPTION....................................... 245 CHARGE VOLT AND AMP VALUES.......................................... 245 BATTERY............................................................. 245 Maintenance and Service......................................... 245 Troubleshooting................................................. 246 Undercharging................................................... 246 Overcharging.................................................... 246 Corrosion....................................................... 246 Acid Levels..................................................... 246 Non-Use or Storage.............................................. 246 Freezing........................................................ 247 BATTERY CHARGING ALTERNATOR............................................. 248 GENERAL INFORMATION................................................. 248 General Description............................................. 248 Terminal Identification and Location............................ 249 Battery Positive (B+)........................................... 249 Battery Negative (B-)........................................... 249 DC Output (D+).................................................. 249 AC Output (R)................................................... 249 Regulator Harness Plug Identification........................... 249 Alternator Specifications....................................... 249 Performance Curve............................................... 249 Battery/Alternator Terminology.................................. 250 WIRING DIAGRAM...................................................... 252 DIMENSIONS AND TORQUE VALUES........................................ 253 PERIODIC MAINTENANCE................................................ 254 TESTING................................................................. 254 GENERAL INFORMATION................................................. 254 Troubleshooting Alternator (On-Truck)........................... 254 Equipment Required.............................................. 254 Preliminary Checks.............................................. 254 Test Set-up..................................................... 256 Test Procedure.................................................. 257 REGULATOR TESTING................................................... 258 Regulator Bypass Test (No Output)............................... 258 Regulator Bypass Test (Amp Rating).............................. 259 BENCH TESTING....................................................... 260 Equipment....................................................... 260 Identification Record........................................... 260 Advanced Troubleshooting........................................ 260 Bench Test 1: No-Load Test...................................... 260 Bench Test 2: Full Load Test.................................... 261 Bench Test 3: Regulator Bypass Test............................. 261 STATIC TESTING...................................................... 262 Equipment....................................................... 262 Identification Record........................................... 262 Regulator Tester................................................ 262 Check For Shorted Power Transistor.............................. 262 Circuit Tests................................................... 263 FIELD COIL TESTS.................................................... 264 Field Coil Test 1: Check for Open or Shorted Field Coil......... 264 Field Coil Test 2: Check For Grounded Field Coil................ 264 STATOR TESTS........................................................ 265 Stator Test 1: Check For Stator-To-Stator Continuity............ 265 Stator Test 2: Check For Grounded Stators....................... 266 THERMAL SWITCH TEST................................................. 266 Initial Test.................................................... 266 Verifying a Faulty Thermal Switch............................... 267 TROUBLESHOOTING TIPS................................................ 268 ALTERNATOR.............................................................. 272 ALTERNATOR REPAIR................................................... 272 Removal......................................................... 272 Installation.................................................... 274 Special Tools and Lubricants.................................... 274 Epoxy Adhesive.................................................. 275 Liquid Threadlockers............................................ 275 Elastoplastic Silicone Resin.................................... 275 ALTERNATOR EXPLODED VIEW............................................ 277 ALTERNATOR DISASSEMBLY.............................................. 279 Regulator Removal............................................... 279 Fan Removal..................................................... 280 Pulley Removal.................................................. 281 Anti-Drive End Housing Removal.................................. 281 Anti-Drive End Rotor Removal.................................... 283 Drive End Housing Removal....................................... 285 Drive End Rotor Removal......................................... 291 Field Coil Removal.............................................. 292 Drive End and/or Anti-Drive End Stator Removal.................. 294 CLEANING AND INSPECTION............................................. 296 ALTERNATOR ASSEMBLY................................................. 296 Anti-Drive End Stator Installation.............................. 296 Drive End Stator Installation................................... 298 Field Coil Installation......................................... 301 Drive End Bearing Installation.................................. 303 Drive End Rotor Installation.................................... 305 Rotor and Rotor Shaft Installation.............................. 305 Drive End Housing Installation.................................. 306 Anti-Drive End Rotor Installation............................... 310 Anti-Drive End Housing Installation............................. 311 Regulator Installation.......................................... 314 THERMAL SWITCH...................................................... 315 Removal......................................................... 315 Installation.................................................... 317 SUPPORT STAND....................................................... 317 SECTION D11 KOMTRAX PLUS........................................................ 319 KOMTRAX PLUS................................................................ 321 KOMTRAX PLUS BASIC FEATURES............................................. 321 Gather Data......................................................... 321 Convert and Record Data............................................. 321 Communicate Data to Off-Board Systems............................... 322 USING KOMTRAX PLUS...................................................... 323 Turning KOMTRAX Plus ON............................................. 323 Normal KOMTRAX Plus Operation....................................... 323 Turning KOMTRAX Plus OFF............................................ 324 Downloading from the KOMTRAX Plus Controller........................ 324 KOMTRAX PLUS DATA ITEMS................................................. 325 Fault Codes......................................................... 325 Machine History..................................................... 325 KOMTRAX Plus History................................................ 325 Snapshots........................................................... 326 Manual Snapshots.................................................... 326 Trends.............................................................. 328 Histogram (Load Map) Data........................................... 328 Haul Cycle Data..................................................... 329 Alarm and Snapshot Triggers......................................... 330 Satellite Features.................................................. 330 KOMTRAX PLUS DIAGNOSTIC FEATURES........................................ 332 Fault History....................................................... 332 LED Digits.......................................................... 332 KOMTRAX PLUS CONTROLLER................................................. 332 Removal............................................................. 333 Installation........................................................ 333 KOMTRAX PLUS SOFTWARE................................................... 334 VHMS Tool Box Installation.......................................... 334 VHMS Setting Tool Installation...................................... 334 PDM Software Installation........................................... 334 KOMTRAX PLUS INITIALIZATION PROCEDURE................................... 335 CONTROLLER SETUP PROCEDURE.......................................... 335 SNAPSHOT PROCEDURE.................................................. 338 DOWNLOAD PROCEDURE.................................................. 339 FTP UPLOAD PROCEDURE................................................ 340 INITIALIZATION FORMS................................................ 341 WHEN REPLACING A KOMTRAX PLUS CONTROLLER................................ 342 KOMTRAX PLUS CONTROLLER CHECKOUT........................................ 347 Necessary Equipment................................................. 347 Preliminary......................................................... 347 KOMTRAX Plus Controller Checkout Procedure.......................... 348 ORBCOMM CONTROLLER (if equipped)........................................ 350 Removal............................................................. 350 Installation........................................................ 350 SECTION D12 INTERFACE MODULE.................................................... 351 INTERFACE MODULE............................................................ 353 Removal................................................................. 353 Installation............................................................ 353 SENSORS..................................................................... 354 Temperature Sensors..................................................... 354 Pressure Sensors........................................................ 354 INTERFACE MODULE SOFTWARE................................................... 355 Flashburn Program Installation.......................................... 355 Interface Module Application Code Installation.......................... 356 Interface Module Realtime Data Monitor Software......................... 356 INTERFACE MODULE CHECKOUT................................................... 357 Necessary Equipment..................................................... 357 Preliminary............................................................. 358 Check Digital Inputs To The Interface Module............................ 359 Check Analog Inputs To The Interface Module............................. 361 Check Serial Interfaces To The Interface Module......................... 361 Check Outputs From The Interface Module................................. 362 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING................... 363 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING........................... 365 GENERAL................................................................. 365 TROUBLESHOOTING......................................................... 366 Communications Networks............................................. 366 Coaxial Cable....................................................... 366 FAULT CODES............................................................. 366 Fault History....................................................... 366 KOMTRAX Plus LED Display Fault Codes................................ 367 Chassis Fault Codes................................................. 368 Engine Fault Codes.................................................. 371 FAULT TREE ANALYSIS..................................................... 377 Unable to connect to KOMTRAX Plus from laptop PC.................... 377 Flashing Error Code N4-23 (PLM III Communications Fault)............ 378 Flashing Error Code N4-22 (Engine Communications Fault)............. 379 No Data Received By WebCARE......................................... 380 Coaxial Cable Troubleshooting....................................... 381 SECTION D14 KOMTRAX PLUS FORMS.................................................. 383 KOMTRAX PLUS FORMS.......................................................... 385 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................. 385 KOMTRAX PLUS DATA DOWNLOAD.............................................. 386 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................. 387 KOMTRAX PLUS INITIALIZATION FORM........................................ 389 SECTION E ELECTRIC PROPULSION SYSTEM................................................ 391 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS................................ 393 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................... 395 GENERAL SYSTEM DESCRIPTION.............................................. 395 SYSTEM COMPONENTS....................................................... 397 Propulsion System Controller (PSC).................................. 397 Truck Control Interface (TCI)....................................... 398 Diagnostic Information Display (DID) Panel.......................... 399 DID Panel Event Codes............................................... 399 PSC SOFTWARE FUNCTIONS.................................................. 418 Input Processing.................................................... 418 State Machine....................................................... 418 DC Link State....................................................... 421 Engine Control...................................................... 422 ALTERNATOR FIELD CONTROL................................................ 422 Desired Three-Phase Voltage......................................... 422 Desired DC Link Voltage............................................. 422 Self-Load........................................................... 423 Propel Torque Control............................................... 423 Retard Torque Control............................................... 423 Wheel Slide Control................................................. 424 Resistor Grid Control............................................... 424 Chopper Voltage Control............................................. 424 EVENT DETECTION AND PROCESSING.......................................... 424 Power-On Tests...................................................... 424 Initiated Tests..................................................... 425 Periodic Tests...................................................... 425 EVENT RESTRICTIONS...................................................... 425 EVENT LOGGING AND STORAGE............................................... 425 Event History Buffer................................................ 426 Data Packs.......................................................... 426 To Record and Save a Data Pack to a Disk............................ 426 Event Reset......................................................... 427 SERIAL DATA COMMUNICATIONS.............................................. 427 PSC - TCI Communications Processing................................. 427 PSC - PTU Communications Processing................................. 427 Inverter Communications Processing.................................. 428 OUTPUT PROCESSING....................................................... 428 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................ 428 Fast Start.......................................................... 428 Engine Shutdown/Engine Not Running.................................. 428 Limp Home Mode...................................................... 429 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................... 430 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................ 438 Removal............................................................. 438 Installation........................................................ 438 Disassembly......................................................... 438 Assembly............................................................ 438 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE........................ 439 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................... 441 AC DRIVE SYSTEM MAINTENANCE............................................. 441 NORMAL TRUCK SHUTDOWN PROCEDURE......................................... 442 SHUTDOWN AFTER SYSTEM FAILURE........................................... 442 SYSTEM CHECKOUT......................................................... 443 Battery and Control Circuit Checks - Battery Power OFF.............. 443 Battery and Control Circuit Checks - Battery Power ON............... 446 Checks with Key Switch OFF.......................................... 447 Checks with Key Switch ON........................................... 447 CPU Battery Checks.................................................. 447 MEMORY BACKUP BATTERY REPLACEMENT....................................... 448 TCI PROGRAMMING......................................................... 448 PSC PROGRAMMING......................................................... 449 INVERTER PROGRAMMING.................................................... 449 CPU RESET............................................................... 449 PSC CHECKOUT............................................................ 450 PSC Digital Input Checks............................................ 450 PSC Digital Output Checks........................................... 454 TCI CHECKOUT............................................................ 455 Modular Mining Communication Port Check............................. 455 TCI Digital Input Checks............................................ 455 TCI Digital Output Tests............................................ 461 CALIBRATIONS............................................................ 463 Speedometer......................................................... 463 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................ 463 ERASING EVENTS.......................................................... 463 PSC................................................................. 463 TCI................................................................. 464 GATE DRIVER POWER CONVERTER TEST........................................ 464 LOAD TESTING............................................................ 465 Preparation......................................................... 465 Alternator Speed Sensor Checks...................................... 465 Battery Boost Check................................................. 465 Brake Circuit Switch Checks......................................... 466 Hoist & Steering Circuit Switch Checks.............................. 466 Link Energized Checks............................................... 466 Loadbox Test........................................................ 468 TROUBLESHOOTING......................................................... 472 PVM Optimum Load Curve Handshaking Troubleshooting.................. 472 Phase Module and Chopper Module Troubleshooting..................... 472 PHASE MODULE REPLACEMENT................................................ 473 Phase Module Removal................................................ 473 Phase Module Installation........................................... 473 SECTION G REAR AXLE, SPINDLES AND WHEELS............................................ 475 SECTION G2 TIRES AND RIMS....................................................... 477 TIRES AND RIMS.............................................................. 479 WHEEL STUD MAINTENANCE.................................................. 480 FRONT TIRES AND RIMS.................................................... 481 Removal............................................................. 481 Installation........................................................ 482 REAR TIRES AND RIMS..................................................... 483 Removal............................................................. 483 Installation........................................................ 484 RIM..................................................................... 485 Tire Removal........................................................ 485 Tire Installation................................................... 485 SECTION G3 FRONT WHEEL HUB AND SPINDLE.......................................... 487 FRONT WHEEL HUB AND SPINDLE................................................. 489 WHEEL HUB AND SPINDLE ASSEMBLY.......................................... 489 Removal............................................................. 489 Spindle Removal Procedure (off of the truck)........................ 492 Installation........................................................ 494 Disassembly......................................................... 495 Cleaning and Inspection............................................. 497 Assembly............................................................ 497 Wheel Bearing Adjustment............................................ 498 Brake Installation.................................................. 499 Seal Assembly Gap Check............................................. 500 WHEEL SPEED SENSOR TESTING.............................................. 501 STEERING CYLINDERS...................................................... 502 Spherical Bearing Wear Limits....................................... 502 Removal............................................................. 503 Installation........................................................ 503 Bearing Replacement (Steering Cylinder and Tie Rod)................. 503 TIE ROD................................................................. 505 Removal............................................................. 505 Installation........................................................ 505 Disassembly......................................................... 506 Assembly............................................................ 506 Toe-In Adjustment................................................... 507 TIE ROD INSPECTION AND TORQUE PROCEDURE................................. 508 Old Style Tie Rod................................................... 508 New Style Tie Rod................................................... 509 SECTION G4 REAR AXLE MOUNTING................................................... 511 REAR AXLE MOUNTING.......................................................... 513 PIVOT PIN............................................................... 513 Removal............................................................. 513 Installation........................................................ 514 PIVOT EYE BEARING....................................................... 515 Removal............................................................. 515 Installation........................................................ 515 PIVOT EYE REPAIR........................................................ 515 Removal............................................................. 515 Disassembly......................................................... 515 Assembly............................................................ 516 Installation........................................................ 516 ANTI-SWAY BAR........................................................... 516 Removal............................................................. 516 Disassembly......................................................... 517 Cleaning and Inspection............................................. 517 Assembly............................................................ 517 Installation........................................................ 517 SECTION G5 REAR AXLE AND WHEEL MOTOR............................................ 519 REAR AXLE AND WHEEL MOTOR................................................... 521 REAR AXLE HOUSING....................................................... 521 Preparation......................................................... 521 Removal............................................................. 522 Cleaning and Inspection............................................. 523 Installation........................................................ 523 BLOWER PRESSURE SWITCH ADJUSTMENT....................................... 523 WHEEL MOTOR............................................................. 524 Preparation......................................................... 524 Removal............................................................. 525 Cleaning and Inspection............................................. 527 Installation........................................................ 527 WHEEL MOTOR GEAR OIL.................................................... 532 Filtering Requirements.............................................. 532 Particle Size Analysis.............................................. 532 Flushing............................................................ 532 Oil Sample Analysis................................................. 533 ELEMENT SPECIFICATION CHARTS............................................ 534 SECTION H HYDRAIR® II SUSPENSIONS................................................... 537 SECTION H2 FRONT SUSPENSIONS.................................................... 539 FRONT SUSPENSION............................................................ 541 Removal................................................................. 541 Installation............................................................ 542 Inspection.............................................................. 547 LOWER BEARING & SEALS................................................... 548 Removal............................................................. 548 Installation........................................................ 548 MAJOR SUSPENSION REBUILD................................................ 549 Disassembly......................................................... 549 Assembly............................................................ 550 SUSPENSION PRESSURE TEST................................................ 551 SECTION H3 REAR SUSPENSIONS..................................................... 553 REAR SUSPENSIONS............................................................ 555 SUSPENSION CYLINDER..................................................... 556 Removal............................................................. 556 Installation........................................................ 558 Disassembly......................................................... 558 Cleaning and Inspection............................................. 559 Assembly............................................................ 559 SUSPENSION PRESSURE TEST................................................ 561 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES............................ 563 SUSPENSION OILING AND CHARGING PROCEDURE.................................... 565 GENERAL................................................................. 565 EQUIPMENT LIST.......................................................... 565 HYDRAIR® CHARGING KIT................................................... 566 Installation of Charging Kit........................................ 566 Removal of Charging Kit............................................. 566 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................... 567 FRONT SUSPENSION........................................................ 567 Front Suspension Oiling............................................. 567 Front Suspension Nitrogen Charging.................................. 569 REAR SUSPENSION......................................................... 570 Rear Suspension Oiling.............................................. 571 Rear Suspension Nitrogen Charging................................... 573 OIL AND NITROGEN SPECIFICATIONS CHARTS...................................... 574 SECTION J BRAKE CIRCUIT............................................................. 575 SECTION J2 BRAKE CIRCUIT........................................................ 577 BRAKE CIRCUIT............................................................... 579 SERVICE BRAKE CIRCUIT................................................... 579 PARKING BRAKE CIRCUIT................................................... 581 BRAKE LOCK CIRCUIT...................................................... 581 SECONDARY BRAKING AND AUTOMATIC APPLY................................... 582 WARNING CIRCUIT......................................................... 582 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE...................................... 585 BRAKE CIRCUIT COMPONENT SERVICE............................................. 587 BRAKE VALVE............................................................. 587 Rebuild Criteria.................................................... 587 Removal............................................................. 588 Installation........................................................ 588 Disassembly......................................................... 589 Cleaning and Inspection............................................. 592 Assembly............................................................ 592 Regulator Sleeve O-Ring Installation................................ 593 BRAKE VALVE BENCH TEST AND ADJUSTMENT................................... 595 Test Setup Procedure................................................ 596 Brake Valve Output Pressure Adjustment.............................. 596 Final Test and Adjustment........................................... 597 Installing Brake Pedal Actuator Assembly to Brake Valve............. 597 Installing Retard Pedal To Brake Pedal.............................. 597 DUAL RELAY VALVE........................................................ 598 Removal............................................................. 598 Installation........................................................ 598 Disassembly......................................................... 598 Cleaning and Inspection............................................. 599 Assembly............................................................ 600 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT.............................. 601 Test Setup Procedure................................................ 602 Relay Valve Output Pressure Adjustment.............................. 602 BRAKE MANIFOLD.......................................................... 603 Removal............................................................. 603 Installation........................................................ 603 Disassembly......................................................... 603 Cleaning and Inspection............................................. 604 Assembly............................................................ 604 BRAKE ACCUMULATORS...................................................... 604 Brake Accumulator Bleeddown Procedure............................... 604 Removal............................................................. 605 Installation........................................................ 605 Disassembly......................................................... 606 Cleaning and Inspection............................................. 607 Assembly............................................................ 607 Accumulator Charging Procedure...................................... 609 Precharge Maintenance............................................... 611 Accumulator Storage Procedures...................................... 612 Bladder Storage Procedures.......................................... 612 Installing A Bladder Accumulator From Storage....................... 612 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)........................ 613 Removal............................................................. 613 Installation........................................................ 613 Disassembly......................................................... 613 Lever Adjustments................................................... 613 Potentiometer Check................................................. 614 Assembly............................................................ 614 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................... 617 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................... 619 REQUIRED EQUIPMENT...................................................... 620 INITIAL SYSTEM SETUP.................................................... 621 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................. 622 PARKING BRAKE CHECK-OUT................................................. 623 SERVICE BRAKE CHECK-OUT................................................. 624 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT....................... 625 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART......................... 626 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET....................... 628 SECTION J5 WET DISC BRAKE ASSEMBLY.............................................. 631 WET DISC BRAKE ASSEMBLY..................................................... 633 OPERATION............................................................... 633 BRAKE DISC WEAR INSPECTION.............................................. 634 BRAKE REBUILD........................................................... 635 Disassembly......................................................... 635 Cleaning and Inspection............................................. 639 Assembly............................................................ 640 Floating Ring Seal Assembly & Installation.......................... 645 WET DISC BRAKE BLEEDING PROCEDURE....................................... 649 SECTION J7 PARKING BRAKE........................................................ 651 PARKING BRAKE............................................................... 653 OPERATION............................................................... 653 MAINTENANCE............................................................. 654 Inspection.......................................................... 654 Removal............................................................. 654 Installation........................................................ 655 Disassembly......................................................... 655 Cleaning and Inspection............................................. 655 Assembly............................................................ 657 Cleaning and Inspecting New Discs................................... 658 PARKING BRAKE BLEEDING PROCEDURE........................................ 659 SECTION L HYDRAULIC SYSTEM.......................................................... 661 SECTION L2 HYDRAULIC SYSTEM..................................................... 663 HYDRAULIC SYSTEM............................................................ 665 HYDRAULIC PUMP MODULE................................................... 665 HOIST CIRCUIT OPERATION................................................. 666 STEERING CIRCUIT OPERATION.............................................. 668 DISC BRAKE COOLING SYSTEM............................................... 670 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR.................................... 673 HYDRAULIC SYSTEM COMPONENT REPAIR........................................... 675 HOIST PUMP.............................................................. 675 Removal............................................................. 675 Installation........................................................ 677 Inspection.......................................................... 682 Assembly............................................................ 682 HYDRAULIC TANK.......................................................... 688 Removal............................................................. 688 Installation........................................................ 689 HYDRAULIC TANK BREATHERS................................................ 689 HYDRAULIC TANK STRAINERS................................................ 690 Removal............................................................. 690 Inspect and Clean................................................... 690 Installation........................................................ 690 SECTION L4 STEERING CIRCUIT..................................................... 691 STEERING CIRCUIT............................................................ 693 STEERING CIRCUIT OPERATION.............................................. 693 COMPONENT DESCRIPTION................................................... 694 Steering Control Unit............................................... 694 Bleeddown Manifold.................................................. 695 Steering Accumulator Bleed Down Solenoid............................ 695 Relief Valves....................................................... 697 Hoist Up Limit Solenoid............................................. 697 Steering Accumulators............................................... 697 Low Precharge Warning Switch........................................ 697 High Pressure Filter................................................ 697 Quick Disconnect Ports.............................................. 697 Flow Amplifier...................................................... 699 FLOW AMPLIFIER SYSTEM OPERATION......................................... 700 No Steer............................................................ 700 Steering Left....................................................... 702 Steering Right...................................................... 704 No Steer, External Shock Load....................................... 706 STEERING PUMP........................................................... 708 Normal Operation.................................................... 708 PRINCIPLE OF OPERATION.................................................. 710 Full Pump Volume.................................................... 710 Half Pump Volume.................................................... 710 Neutral Position.................................................... 710 Steering Pump....................................................... 711 SECTION L5 STEERING CONTROL UNIT................................................ 713 STEERING CONTROL UNIT....................................................... 715 REMOVAL................................................................. 715 SPLINE INSPECTION....................................................... 715 INSTALLATION............................................................ 716 DISASSEMBLY............................................................. 716 CLEANING AND INSPECTION................................................. 717 ASSEMBLY................................................................ 719 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR.................................... 723 STEERING CIRCUIT COMPONENT REPAIR........................................... 725 BLEEDDOWN MANIFOLD VALVE................................................ 725 Removal............................................................. 725 Installation........................................................ 726 FLOW AMPLIFIER.......................................................... 727 Removal............................................................. 727 Installation........................................................ 727 Disassembly......................................................... 727 Assembly............................................................ 729 STEERING CYLINDERS...................................................... 730 Disassembly......................................................... 731 Piston Seal & Bearing Installation.................................. 731 Assembly............................................................ 731 Testing............................................................. 731 STEERING AND BRAKE PUMP................................................. 732 Removal............................................................. 732 Installation........................................................ 733 Disassembly......................................................... 734 Inspection.......................................................... 737 Assembly............................................................ 740 Driveshaft Group.................................................... 741 Rotating Group...................................................... 741 Valve Plate Group................................................... 742 STEERING ACCUMULATORS................................................... 744 Removal............................................................. 744 Installation........................................................ 744 Disassembly......................................................... 745 Cleaning and Inspection............................................. 745 Assembly............................................................ 746 Leak Testing........................................................ 748 Charging Procedure.................................................. 749 Precharge Maintenance............................................... 751 Accumulator Storage Procedures...................................... 752 Bladder Storage Procedures.......................................... 752 Installing A Bladder Accumulator From Storage....................... 752 TROUBLESHOOTING CHART....................................................... 753 SECTION L7 HOIST CIRCUIT........................................................ 757 HOIST CIRCUIT............................................................... 759 BASIC OPERATION......................................................... 759 COMPONENT DESCRIPTION................................................... 760 Hydraulic Tank...................................................... 760 Hydraulic Pump...................................................... 760 High Pressure Filters............................................... 760 Hoist Valve......................................................... 760 Inlet Sections...................................................... 760 Work Ports (Rear) Spool Section..................................... 761 Tank Ports (Front) Spool Section.................................... 761 Hoist Pilot Valve................................................... 761 Bleeddown Manifold.................................................. 762 Hoist Up Limit Solenoid............................................. 762 Pilot Operated Check Valve.......................................... 762 Overcenter Manifold................................................. 762 HOIST CIRCUIT OPERATION..................................................... 763 Float Position Of Pilot Valve With Truck Body On Frame.................. 764 Power Up Operation...................................................... 766 Hold Operation.......................................................... 768 Power Down Operation.................................................... 770 Float Operation......................................................... 772 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR....................................... 775 HOIST CIRCUIT COMPONENT REPAIR.............................................. 777 HOIST VALVE............................................................. 777 Removal............................................................. 777 Installation........................................................ 778 O-Ring Replacement.................................................. 778 INLET SECTION........................................................... 779 Cleaning and Inspection............................................. 780 Assembly............................................................ 780 REAR SPOOL SECTION (Work Ports)......................................... 781 Disassembly......................................................... 781 Cleaning and Inspection............................................. 781 Assembly............................................................ 783 FRONT SPOOL SECTION (Tank Ports)........................................ 784 Disassembly......................................................... 784 Cleaning and Inspection............................................. 784 Assembly............................................................ 784 HOIST PILOT VALVE....................................................... 786 Removal............................................................. 786 Installation........................................................ 786 Disassembly......................................................... 787 Cleaning and Inspection............................................. 788 Assembly............................................................ 788 HOIST CYLINDERS......................................................... 789 Removal............................................................. 789 Installation........................................................ 790 Disassembly......................................................... 792 Cleaning and Inspection............................................. 793 Assembly - Quill.................................................... 794 Assembly - Cylinder................................................. 796 Testing............................................................. 796 OVERCENTER VALVE MANIFOLD............................................... 797 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................. 799 HYDRAULIC SYSTEM FILTERS.................................................... 801 HOIST CIRCUIT FILTER.................................................... 801 Filter Element Replacement.......................................... 801 Removal - Hoist Circuit Filter...................................... 802 Installation - Hoist Circuit Filter................................. 802 Indicator Switch - Hoist Circuit Filter............................. 802 STEERING CIRCUIT FILTER................................................. 803 Filter Element Replacement.......................................... 803 Removal - Steering Circuit Filter................................... 804 Installation - Steering Circuit Filter.............................. 804 Indicator Switch - Steering Circuit Filter.......................... 804 INDICATOR SWITCH........................................................ 804 Test Procedure...................................................... 804 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE........................................ 807 HYDRAULIC CHECKOUT PROCEDURE................................................ 809 GENERAL INFORMATION..................................................... 809 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE....................... 816 Equipment Requirements.............................................. 817 Pump Pressure Control Adjustments................................... 817 Steering Control Valve and Flow Amplifier Leakage Test.............. 818 Bleeddown Manifold Leakage Test..................................... 819 STEERING/BRAKE PUMP STROKE ADJUSTMENT................................... 820 SHOCK AND SUCTION VALVES................................................ 820 Equipment Requirements.............................................. 820 Pressure Tests...................................................... 820 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES........... 822 Equipment Requirements.............................................. 822 Pressure Gauge Locations............................................ 822 Brake Cooling Circuit Test.......................................... 822 Power Up Relief Pressure Test....................................... 823 Power Down Relief Pressure Test..................................... 824 Counterbalance Valve Pressure Check................................. 825 Counterbalance Valve Adjustment..................................... 826 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET....................... 827 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET.......... 828 SECTION M OPTIONS AND SPECIAL TOOLS................................................. 829 SECTION M7 HOT START SYSTEM..................................................... 831 HOT START SYSTEM............................................................ 833 SYSTEM OPERATION........................................................ 833 HEATER INFORMATION...................................................... 834 TROUBLESHOOTING GUIDELINES.............................................. 835 SECTION M8 SPECIAL TOOLS........................................................ 837 HIGH VOLTAGE TOOLS.......................................................... 842 0-2000 VDC CUSTOM METER KIT (58B-06-00800).................................. 842 SECTION M19 RADIATOR SHUTTERS................................................... 845 RADIATOR SHUTTERS........................................................... 847 OPERATION............................................................... 847 Hydraulic Circuit................................................... 847 Electrical Circuit.................................................. 848 MAINTENANCE AND REPAIR.................................................. 848 TROUBLESHOOTING......................................................... 849 SECTION M20 PAYLOAD METER III ™................................................. 853 OPERATION SECTION........................................................... 857 Introduction............................................................ 857 Data Summary........................................................ 857 Data Gathering...................................................... 857 COMPONENT DESCRIPTION................................................... 858 System Diagram...................................................... 858 Suspension Pressure Sensors......................................... 858 Inclinometer........................................................ 858 Operator Display.................................................... 858 Operator Switch..................................................... 859 Speed Input......................................................... 859 Body-Up Switch...................................................... 859 Brake Lock Switch................................................... 859 Payload Meter....................................................... 859 Communications Ports................................................ 859 Key Switch Input.................................................... 860 Payload Meter Power................................................. 860 Load Lights......................................................... 860 Wiring and Termination.............................................. 861 TCI Outputs......................................................... 861 OPERATOR’S DISPLAY AND SWITCH........................................... 862 Reading the Speedometer............................................. 862 Reading the Load Display............................................ 862 Using the Operator ID............................................... 862 Using the Load and Ton Counter...................................... 862 Total Ton Counter................................................... 862 Total Load Counter.................................................. 863 Clearing the Counters............................................... 863 Viewing Live Sensor Data............................................ 863 Other Display Messages.............................................. 863 PAYLOAD OPERATION & CALCULATION......................................... 864 Description of Haul Cycle States.................................... 864 Haul Cycle Description.............................................. 864 Load Calculation.................................................... 865 Carry Back.......................................................... 865 Measurement Accuracy................................................ 865 SOURCES FOR PAYLOAD ERROR............................................... 865 Payload Error....................................................... 865 Loading Conditions.................................................. 866 Pressure Sensors.................................................... 866 Swingloads.......................................................... 866 Speed and Distance.................................................. 866 HAUL CYCLE DATA......................................................... 866 Haul Cycle Warning Flags............................................ 868 Frame Torque Data................................................... 869 Sprung Weight Data.................................................. 869 Maximum Speed Data.................................................. 869 Alarm Records....................................................... 869 Fault Code Data..................................................... 870 PC SOFTWARE OVERVIEW.................................................... 871 System Configuration................................................ 871 Installing the PLMIII Software...................................... 871 DOWNLOADING DATA........................................................ 872 PLM III SYSTEM CONFIGURATION............................................ 873 Starting Communications............................................. 873 Displayed Payload Units............................................. 873 Time Units.......................................................... 873 Connection Menu..................................................... 873 Connecting to the Payload Meter..................................... 874 Configure the Payload Meter......................................... 874 Setting the Date and Time........................................... 874 Setting the Truck Type.............................................. 875 Setting the Gauge Display Units..................................... 875 Setting the Frame Serial Number..................................... 875 Setting the Truck Number............................................ 875 Setting the Komatsu Distributor..................................... 875 Setting the Komatsu Customer........................................ 875 Clean Truck Tare Calibration........................................ 876 Inclinometer Calibration............................................ 876 DATA ANALYSIS........................................................... 877 Creating a Query.................................................... 877 Sorting on Truck Unit Number........................................ 877 Sorting on Truck Type............................................... 877 Sorting on Date Range............................................... 878 Sorting on Time Range............................................... 878 Payload Detail Screen............................................... 879 Creating Reports.................................................... 879 Summary - one page report........................................... 880 Detailed - multi-page report........................................ 880 Creating Graphs..................................................... 881 Exporting Data...................................................... 881 CSV Export.......................................................... 881 Compressed.......................................................... 882 Importing Data...................................................... 883 Deleting Haul Cycle Records......................................... 883 Viewing Alarms...................................................... 884 Deleting Alarm Records.............................................. 884 TROUBLESHOOTING SECTION..................................................... 885 TROUBLESHOOTING......................................................... 885 Viewing Active Alarms............................................... 885 Real-Time Data Display.............................................. 885 Testing the Payload Lights.......................................... 885 Creating Log Files of Inputs........................................ 886 Daily Inspections................................................... 886 Periodic Maintenance................................................ 886 Abnormal Displays at Power-Up....................................... 887 No Payload Display When Key Switch is Turned ON..................... 888 No Display on Speedometer........................................... 889 No Display on Operator Display...................................... 889 No Communications With PC........................................... 890 Load Lights Don’t Light During Loading.............................. 891 Load Lights Remain ON............................................... 892 Load Lights Remain ON During Dumping................................ 892 Display Doesn't Clear When The Load Is Dumped....................... 892 Calibration Problems................................................ 893 Alarm 1 - Left Front Pressure High.................................. 894 Alarm 2 - Left Front Pressure Low................................... 894 Troubleshoot Wiring to Left Front Suspension........................ 894 Alarm 3 - Right Front Pressure High................................. 895 Alarm 4 - Right Front Pressure Low.................................. 895 Troubleshoot Wiring to Right Front Suspension....................... 895 Alarm 5 -Left Rear Pressure High.................................... 896 Alarm 6 - Left Rear Pressure Low.................................... 896 Troubleshoot Wiring to Left Rear Suspension......................... 896 Alarm 7 - Right Rear Pressure High.................................. 897 Alarm 8 - Right Rear Pressure Low................................... 897 Troubleshoot Wiring to Right Rear Suspension........................ 897 Alarm 9 - Inclinometer High......................................... 898 Alarm 10 - Inclinometer Low......................................... 898 Troubleshoot Inclinometer Wiring.................................... 898 Alarm 13 - Body Up Input Failure.................................... 899 Alarm 16 - Memory Write Failure..................................... 900 Alarm 17 - Memory Read Failure...................................... 900 Alarm 18............................................................ 901 Alarm 19............................................................ 901 Alarm 22............................................................ 901 Operator Switch Doesn't Work........................................ 902 Alarm 26 - User Switch Fault - SELECT............................... 902 Alarm 27 - User Switch Fault - SET.................................. 902 Connector Map....................................................... 903 Connectors.......................................................... 904 PLMIII CHECK OUT PROCEDURE.................................................. 905 General Description..................................................... 905 Tools Required.......................................................... 905 Checkout Procedure...................................................... 905 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................. 909 Flashburn Programming............................................... 909 Confirmation Checklist.............................................. 911 SECTION M31 RESERVE ENGINE OIL SYSTEM........................................... 913 RESERVE ENGINE OIL SYSTEM................................................... 915 Operation............................................................... 916 LED Monitor Light....................................................... 916 Tank Fill Control (Optional)............................................ 917 Filling Procedure (Remote Fill Feature)................................. 917 SERVICE................................................................. 918 Every 10 Hours, or once each shift:................................. 918 Every 500 Hours..................................................... 918 Changing Oil........................................................ 918 TROUBLESHOOTING......................................................... 919 Circuit Fuse........................................................ 919 SYSTEM ELECTRICAL SCHEMATICS............................................ 920 SECTION N OPERATOR CAB.............................................................. 921 SECTION N2 TRUCK CAB AND COMPONENTS............................................. 923 TRUCK CAB AND COMPONENTS.................................................... 925 TRUCK CAB............................................................... 925 Description......................................................... 925 Removal............................................................. 926 Installation........................................................ 927 CAB DOOR................................................................ 928 Removal............................................................. 928 Installation........................................................ 928 Door Jamb Bolt Adjustment........................................... 929 Door Handle Plunger Adjustment...................................... 930 Replacing the Door Glass............................................ 931 Replacing the Door Handle or Latch Assembly......................... 935 Replacing the Door Window Regulator................................. 936 Replacing the Door and Door Hinge Seal.............................. 937 Replacing the Door Opening Seal..................................... 937 GLASS REPLACEMENT (Adhesive-Bonded Windows)............................. 938 Recommended Tools and Supplies...................................... 938 Replacement Procedure............................................... 938 WINDSHIELD AND REAR GLASS............................................... 939 Removal............................................................. 939 Installation........................................................ 940 SECTION N3 CAB COMPONENTS....................................................... 941 CAB COMPONENTS.............................................................. 943 WINDSHIELD WIPERS....................................................... 943 WIPER MOTOR......................................................... 943 Removal......................................................... 943 Installation.................................................... 943 WIPER ARM........................................................... 943 Removal......................................................... 943 Installation.................................................... 944 WIPER LINKAGE....................................................... 944 Removal......................................................... 944 Installation.................................................... 944 WINDSHIELD WASHER....................................................... 945 Operation........................................................... 945 Service............................................................. 945 OPERATOR SEAT........................................................... 946 Seat Belts.......................................................... 946 Adjustment.......................................................... 946 Inspection.......................................................... 947 Removal............................................................. 947 Installation........................................................ 947 PASSENGER SEAT.......................................................... 948 Inspection.......................................................... 948 Removal............................................................. 948 Installation........................................................ 948 SECTION N4 HEATER / AIR CONDITIONER............................................. 949 HEATER/AIR CONDITIONER...................................................... 951 OPERATION............................................................... 951 Fan Control Knob.................................................... 951 Temperature Control Knob............................................ 951 Directional Control Knob............................................ 951 Heater Vents........................................................ 951 COMPONENTS.............................................................. 952 Fuse and Circuit Breaker............................................ 952 Relays.............................................................. 952 Heater Core......................................................... 952 Fan Motor And Speed Control......................................... 953 Actuators........................................................... 953 Cab Air Filter...................................................... 953 ENVIRONMENTAL IMPACT OF AIR CONDITIONING................................ 956 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................... 956 PRINCIPLES OF REFRIGERATION............................................. 956 Air Conditioning.................................................... 956 Refrigeration - The Act Of Cooling.................................. 957 The Refrigeration Cycle............................................. 957 AIR CONDITIONER SYSTEM COMPONENTS....................................... 958 Compressor (Refrigerant Pump)....................................... 958 Service Valves...................................................... 958 Condenser........................................................... 958 Receiver-Drier...................................................... 958 Expansion Block Valve............................................... 959 Accumulator......................................................... 959 Evaporator.......................................................... 959 ELECTRICAL CIRCUIT...................................................... 960 Thermostat.......................................................... 960 Compressor Clutch................................................... 960 Trinary™ Switch..................................................... 961 AIR CONDITIONING SYSTEM SERVICING WARNINGS.............................. 962 SERVICE TOOLS AND EQUIPMENT............................................. 963 Recovery/Recycle Station............................................ 963 Leak Detector....................................................... 963 Manifold Gauge Set.................................................. 964 Installing Manifold Gauge Set....................................... 965 Purging Air From Service Hoses...................................... 965 Service Valves...................................................... 966 Vacuum Pump......................................................... 966 SYSTEM PERFORMANCE TEST................................................. 967 SYSTEM OIL.............................................................. 968 Handling and Reusing PAG Oil........................................ 968 Oil Quantity........................................................ 968 Checking System Oil................................................. 968 REFRIGERANT............................................................. 969 Recycled Refrigerant................................................ 969 Reclaimed Refrigerant............................................... 969 Refrigerant Quantity................................................ 970 R-134a Refrigerant Containers....................................... 970 SYSTEM LEAK TESTING..................................................... 970 Electronic Leak Detector............................................ 971 Tracer Dyes......................................................... 971 Soap and Water...................................................... 971 RECOVERING AND RECYCLING THE REFRIGERANT................................ 971 Draining Oil from the Previous Recovery Cycle....................... 971 Performing the Recovery Cycle....................................... 971 Performing the Recycling Procedure.................................. 972 Evacuating and Charging the A/C System.............................. 972 SYSTEM REPAIR........................................................... 972 System Flushing..................................................... 972 A/C DRIVE BELT CHECKOUT PROCEDURE....................................... 973 Pulley Alignment.................................................... 973 Belt Tension Check.................................................. 973 COMPONENT REPLACEMENT................................................... 975 Hoses and Fittings.................................................. 975 Lines............................................................... 975 Expansion Valve..................................................... 975 Receiver-Drier...................................................... 975 Thermostat.......................................................... 975 Compressor.......................................................... 976 Accumulator......................................................... 976 Clutch.............................................................. 976 Servicing the Compressor Clutch..................................... 977 Pulley Removal...................................................... 979 Clutch Coil Check................................................... 979 Pulley Installation................................................. 979 Clutch Assembly Installation........................................ 980 EVACUATING THE SYSTEM................................................... 981 CHARGING THE A/C SYSTEM................................................. 982 TROUBLESHOOTING......................................................... 983 Preliminary Checks.................................................. 983 Diagnosis Of Gauge Readings And System Performance.................. 983 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.............................. 984 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.............................. 990 SECTION N5 OPERATOR CAB CONTROLS................................................ 991 OPERATOR CAB CONTROLS....................................................... 994 STEERING COLUMN......................................................... 995 Removal............................................................. 995 Inspection.......................................................... 995 Installation........................................................ 996 STEERING WHEEL.......................................................... 996 Removal............................................................. 996 Installation........................................................ 996 STEERING WHEEL AND CONTROLS............................................. 998 Horn Button......................................................... 998 Tilt / Telescope Lever.............................................. 998 Multi-Function Turn Signal Switch................................... 998 DYNAMIC RETARDING....................................................... 999 Retarder Lever...................................................... 999 Brake/Retarder Pedal................................................ 999 Throttle/Accelerator Pedal.......................................... 999 GRADE/SPEED CHART.......................................................1000 OVERHEAD PANEL AND DISPLAYS.............................................1001 Speakers............................................................1001 Warning Alarm Buzzer................................................1001 Radio/CD Player.....................................................1001 Warning Indicator Light Dimmer Control..............................1001 Status/Warning Indicator Light Panel................................1001 Air Cleaner Restriction Gauges......................................1001 CENTER CONSOLE..........................................................1002 Directional Control Lever...........................................1002 Override/Fault Reset Switch.........................................1003 Engine Shutdown Switch..............................................1003 Window Control Switches.............................................1003 Hoist Control Lever.................................................1003 Retarder Speed Control (RSC) Adjustment Dial........................1004 Retarder Speed Control (RSC) Switch.................................1004 Data Store Button...................................................1005 KOMTRAX Plus Snapshot In Progress Light.............................1005 Link Energized Light................................................1005 Service Engine Light................................................1005 12V Auxiliary Power Outlets.........................................1005 DIAGNOSTIC PORTS........................................................1005 KOMTRAX Plus Diagnostic Port........................................1005 Interface Module (IM) Diagnostic Port...............................1005 Payload Meter Diagnostic Port.......................................1005 Truck Control Interface (TCI) Diagnostic Port.......................1005 Propulsion System Controller (PSC) Diagnostic Port..................1005 Engine Diagnostic Port (CENSE)......................................1005 Engine Diagnostic Port (QUANTUM)....................................1005 INSTRUMENT PANEL........................................................1006 Control Symbols.....................................................1006 Key Switch..........................................................1008 Engine Shutdown Timer Switch........................................1008 Air Conditioner Compressor Switch (if equipped).....................1008 Rotating Beacon Switch (optional)...................................1008 Heated Mirrors Switch (optional)....................................1008 AC Drive System Rest Switch.........................................1009 Wheel Brake Lock Switch.............................................1009 Hazard Warning Lights...............................................1009 Heater/Air Conditioner Vents........................................1009 Engine Oil Pressure Gauge...........................................1010 Right Turn Signal Indicator.........................................1010 Digital Tachometer..................................................1010 High Beam Indicator.................................................1010 Speedometer/Payload Meter Display...................................1010 Left Turn Signal Indicator..........................................1010 Coolant Temperature Gauge...........................................1010 Lamp Check Switch...................................................1010 Light Switch (3-Way)................................................1010 Ladder Light Switch.................................................1011 Backup Light Switch.................................................1011 Fog Light Switch....................................................1011 Payload Meter Switch................................................1011 Panel Illumination Light Dimmer Switch..............................1011 Hydraulic Oil Temperature Gauge.....................................1011 Engine Hourmeter....................................................1011 Fuel Gauge..........................................................1011 OVERHEAD STATUS / WARNING INDICATORS....................................1012 A1. High Hydraulic Oil Temperature..................................1013 B1. Low Steering Pressure...........................................1013 C1. Low Accumulator Precharge Pressure..............................1014 D1. Not used........................................................1014 E1. Low Brake Pressure..............................................1014 A2. Low Hydraulic Tank Level........................................1014 B2. Low Automatic Lubrication System Pressure.......................1014 C2. Circuit Breaker Tripped.........................................1014 D2. Hydraulic Oil Filter Monitor....................................1014 E2. Low Fuel........................................................1015 A3. Parking Brake...................................................1015 B3. Service Brake...................................................1015 C3. Body Up.........................................................1015 D3. Dynamic Retarding...............................................1015 E3. Stop Engine.....................................................1015 A4. Cranking Motor Failure..........................................1015 B4. Backup Lights...................................................1015 C4. Engine Shutdown Timer - 5 Minute Idle...........................1016 D4. Retard Speed Control (RSC) Indicator............................1016 E4. Check Engine....................................................1016 A5. No Power........................................................1016 B5. Propulsion System Warning.......................................1016 C5. Propulsion System Temperature...................................1016 D5. System/Component Failure........................................1016 E5. Battery Charging System Failure.................................1017 A6. No Propel.......................................................1017 B6. Propel System At Rest...........................................1017 C6. Propel System Not Ready.........................................1017 D6. Reduced Propulsion..............................................1017 E6. Retard At Continuous Level......................................1017 REAR AXLE LIGHT BAR.....................................................1018 Backup Lights.......................................................1018 Retard Lights.......................................................1018 Brake Light.........................................................1018 Backup Alarm........................................................1018 KOMTRAX PLUS............................................................1019 Operation...........................................................1019 Interface Module....................................................1021 Basic Precautions...................................................1021 KOMATSU WIRELESS BRIDGE (Optional)......................................1022 General Information.................................................1022 Communication Setup.................................................1022 Switching to the KWB_SETUP Network..................................1022 Setting the Computer Subnet Mask and IP Address.....................1023 Properties..........................................................1023 Setting Up the KWB..................................................1024 Adding Encryption...................................................1024 Final Computer Settings.............................................1024 Data Downloading....................................................1025 Resetting the KWB...................................................1025 KWB Lights..........................................................1025 SECTION P LUBRICATION AND SERVICE...................................................1027 SECTION P2 LUBRICATION AND SERVICE..............................................1029 LUBRICATION AND SERVICE.....................................................1031 GENERAL.................................................................1031 SERVICE CAPACITIES......................................................1031 HYDRAULIC TANK SERVICE..................................................1031 Adding Oil..........................................................1031 COOLING SYSTEM SERVICE..................................................1032 Radiator Filling Procedure..........................................1032 Coolant Specifications..............................................1032 Unacceptable Practices..............................................1032 WHEEL MOTOR SERVICE.....................................................1032 RESERVE OIL TANK SERVICE................................................1033 Filling the Reserve Oil Tank (Remote Fill)..........................1033 Inline Screen.......................................................1033 QUICK FILL SERVICE CENTER...............................................1034 LUBRICATION CHART.......................................................1035 10 HOUR (DAILY) INSPECTIONS.............................................1036 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................1038 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................1038 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................1038 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................1041 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................1043 5000 HOUR MAINTENANCE CHECKS............................................1043 SECTION P3 AUTOMATIC LUBRICATION SYSTEM.........................................1045 AUTOMATIC LUBRICATION SYSTEM................................................1047 GENERAL DESCRIPTION.....................................................1047 SYSTEM COMPONENTS.......................................................1049 Filter..............................................................1049 Hydraulic Motor and Pump............................................1049 Grease Reservoir....................................................1049 Pressure Reducing Valve.............................................1049 Flow Control Valve..................................................1049 Solenoid Valve......................................................1049 Vent Valve..........................................................1049 Lubrication Cycle Timer.............................................1049 Over Pressure Cut Off Switch........................................1049 Grease Pressure Failure Switch......................................1049 Injectors...........................................................1049 Relief Valve (unloader valve).......................................1049 SYSTEM OPERATION........................................................1050 Normal Operation....................................................1050 Lubricant Required For System.......................................1051 System Priming......................................................1051 Filter Assembly.....................................................1051 LUBRICANT PUMP..........................................................1052 Pump Housing Oil Level..............................................1052 Pump Pressure Control...............................................1052 INJECTORS (SL-1 Series “H”).............................................1053 Injector Specifications.............................................1053 Injector Adjustment.................................................1053 INJECTOR OPERATION..................................................1054 PREVENTIVE MAINTENANCE PROCEDURES.......................................1055 Daily Lubrication System Inspection.................................1055 250 Hour Inspection.................................................1055 1000 Hour Inspection................................................1055 SYSTEM CHECKOUT.........................................................1056 Lubrication Controller Check........................................1056 Lubrication Controller Components...................................1056 Lubrication Controller Adjustment...................................1056 SYSTEM TROUBLESHOOTING CHART................................................1058 SECTION Q ALPHABETICAL INDEX........................................................1061 SECTION R SYSTEM SCHEMATICS.........................................................1065 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.....................1067 HYDRAULIC BRAKE SYSTEM SCHEMATIC................................................1068 ELECTRICAL SCHEMATICS...........................................................1069
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Zeke Cairo –